Page 1 Turbocharging Operation Manual / A135-M66 HT608054 Document identification Document number HZTL4031 Revision Language English Original Operation Manual Product identification Serial number HT608054 Customer part number 1006365741 Delivery date (yyyy-mm-dd) 2021-11-29 Weight Operating limits according to rating plate Speed limit in test rig operation only Mmax Speed limit during operation Bmax...
Page 3: Table Of Contents
Operation Manual / A130-M.. - A145-M.. Table of contents Operation Manual / A130-M.. - A145-M.. Introduction......................4 Purpose of the manual....................4 Contact information...................... 5 Essential information....................5 Layout and function of the turbocharger ..............6 Symbols, definitions..................... 8 Storage of new turbochargers and spare parts ............ 10 Registered trademarks ....................
Page 4 Operation Manual / A130-M.. - A145-M.. Table of contents Service work ........................57 Expected replacement intervals ................61 Stopping the engine....................63 Periodic maintenance work ................64 Foreword to maintenance..................64 Cleaning the compressor during operation ............65 Cleaning the turbine during operation..............68 Cleaning components mechanically ................
Page 5 Operation Manual / A130-M.. - A145-M.. Table of contents 10.5 Cover plate drawing ....................124 Mothballing the turbocharger................125 11.1 Taking the engine out of operation for up to 12 months ........125 11.2 Taking the engine out of operation for more than 12 months ......126 Disposing of turbocharger components ............
Page 6: Operation Manual / A130-M
Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.1 Purpose of the manual Introduction Purpose of the manual Fig. 1: Serial number (01) on the rating plate This Operation Manual belongs to the turbocharger with the identical serial number (01), see the Operation Manual title page and the rating plate on the turbocharger.
Page 7: Contact Information
This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not relevant for a specific turbocharger variant. Please contact an ABB Turbocharging Service Station if you have any questions regarding a design variant (see Contact information at www.abb.com/turbocharging).
Page 8: Layout And Function Of The Turbocharger
Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.4 Layout and function of the turbocharger Layout and function of the turbocharger Fig. 2: Layout and function of the turbocharger 01 Filter silencer / air suction branch Gas outlet flange 02 Compressor casing...
Page 9: Fig. 3: Compressor Wheel Cooling
Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.4 Layout and function of the turbocharger Mode of operation The turbocharger is a turbomachine and consists of the following main components: ¡ Turbine ¡ Compressor. These components are installed on a common shaft and form the rotor.
Page 10: Symbols, Definitions
Caution and warning signs are described in chapter Safety. ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging. See also chapter Contact information →5.
Page 11: Table 1: Definition Of Pictograms
Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.5 Symbols, definitions Definition of pictograms The following pictograms can occur in this document. These point out actions that must be taken in accordance with the meaning of the relevant pictogram.
Page 12: Storage Of New Turbochargers And Spare Parts
Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.6 Storage of new turbochargers and spare parts Storage of new turbochargers and spare parts Storage of new turbochargers and spare parts up to 6 months New turbochargers and spare parts can be stored in their closed packages for 6 months from the date of delivery without additional mothballing measures.
Page 13: Fig. 5: Package With Hygrometer
Inspect the package for damage. If the package is damaged, the turbocharger must be in- spected by an ABB Turbocharging Service Station and repacked. After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station: ¡...
Page 14: Registered Trademarks
Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.7 Registered trademarks Registered trademarks The trademarks of outside companies are used in this document. These are marked with the ® symbol. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N...
Page 15: Safety
Safety Introduction Turbochargers manufactured by ABB reflect the state of the art. The respective safety and health protection requirements are met. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the tur- bocharger which: ¡...
Page 16: Definition Of Mandatory Signs
Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.3 Definition of mandatory signs Definition of mandatory signs To be worn at all times Protective clothing Safety footwear to protect against mechanical hazard and risk of falling Table 2: Personal protective equipment to be worn at all times...
Page 17: Intended Use
These data are given on the rating plate. ABB accepts no liability and rejects all warranty claims for any non-intended uses. [1]Euromot = The European Association of Internal Combustion Engine Manufacturers [2]Directive 94/9/EC concerning equipment and protective systems intended for use in po-...
Page 18: Deflagration On Gas Engines
If during external inspection anomalies are found or if a particularly strong deflagration event has taken place, it is also recommended to check the bearings of the turbochargers before the next start. An ABB Turbocharging Service Station should be instructed to carry out this inspection.
Page 19: Warning Plates On The Turbocharger
If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates from ABB Turbocharging Service Stations. Remove any warning plates that have become unreadable. Clean and degrease the areas designated for the warning plates.
Page 20: Turbocharger Rating Plate
Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.8 Turbocharger rating plate Turbocharger rating plate Fig. 7: Rating plate Operating limits 01 Turbocharger operating limits at engine overload (110 %). In test rig operation only, unless otherwise agreed with the en- ginebuilder.
Page 21: Fig. 8: Locations Of The Rating Plates
Operation above the indicated values n can considerably shorten the recommended Bmax Bmax replacement intervals. In such cases, we recommend contacting the nearest ABB Turbochar- ging Service Station. normally apply only when running at overload (110 %) during trials on the engine Mmax Mmax test bed.
Page 22: Periodic Check Of The Pressure Vessels
Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.9 Periodic check of the pressure vessels Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ¡...
Page 23: Lifting Of Loads
Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.10 Lifting of loads 2.10 Lifting of loads WARNING Suspended loads Loads that are not attached according to regulations can cause injury to personnel or fatal accidents. Loads must always be fastened to properly functional lifting gear with a sufficient load limit.
Page 24: Prerequisites For Operation And Maintenance
Only use original parts from ABB. Original parts and accessories are specially designed for ABB turbochargers. ABB accepts no liability for any damage resulting from the use of non-original parts and cor- responding accessories. © Copyright 2021 ABB. All rights reserved.
Page 25: Hazards During Operation And Maintenance
Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.12 Hazards during operation and maintenance 2.12 Hazards during operation and maintenance Noise hazards The turbocharger's noise emission is influenced by its installation and operating conditions. A noise level exceeding 85 dB(A) is harmful.
Page 26 Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.12 Hazards during operation and maintenance WARNING Hot surfaces on a non-insulated turbocharger Non-insulated turbochargers can cause serious injuries to personnel (burns). The turbocharger is supplied with or without insulation in accordance with the purchase order received from the enginebuilder.
Page 27: Safe Operation
Variant A Insulation (01) with integrated burst protection from ABB. Variant B Burst protection (03) and insulation (02) from ABB. Variant C Burst protection (03) from ABB with appropriate insulation from the enginebuilder. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 28: Safe Maintenance
Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.14 Safe maintenance 2.14 Safe maintenance Occupational safety WARNING Injuries to persons Severe injuries to personnel or fatal accidents can be caused by mechanical influences as a consequence of hazardous and inadequate operational pro- cedures or non-compliance with safety and health standards.
Page 29 Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.14 Safe maintenance Use of assembly devices Assembly devices are specially constructed and designed for the defined use; they are not commercially available products. Use assembly devices only for the described applications.
Page 30 Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.14 Safe maintenance Safety when taking out of operation or preparing for mothballing Observe the material safety data sheet for the cleaning and mothballing agents. Wear personal protective equipment (PPE) according to the material safety data sheet.
Page 31 Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.14 Safe maintenance WARNING Danger of fire or explosion Flammable and combustible operating materials and supplies can catch fire or resulting vapours can lead to an explosion. Observe the information in the material safety data sheet for the operat- ing materials and supplies.
Page 32: Removing And Installing
Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.1 Turbocharger weight and transporta- tion Removing and Installing Turbocharger weight and transportation Lifting gear with a sufficient load limit must be used for removing, installing and transport- ing the turbocharger. The weight specified below applies to the heaviest variant possible.
Page 33: Removing The Turbocharger
Observe the specified tightening torque from the supplier of the screw connection. Components (01/02) are not included in the ABB scope of delivery. Fig. 13: Turbine cleaning nozzle 1. If present: Loosen the turbine cleaning connection (01).
Page 34: Fig. 14: Removing The Turbocharger
Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.2 Removing the turbocharger The gas outlet casing (61001) can remain fitted in the exhaust gas pipe if the locking nuts are accessible. Otherwise the complete turbocharger unit including gas outlet casing must be removed.
Page 35 Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.2 Removing the turbocharger Version with water cooling CAUTION Freezing of the cooling water in the bearing casing If cooling water freezes in the bearing casing, this can lead to severe dam- age.
Page 36: Fig. 15: Loosening The Clamping Nut
Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.2 Removing the turbocharger 3.2.2 Loosening the clamping nut CAUTION Incorrect procedure can make loosening impossible If individual pressure screws are fully relieved, the pressure screws can be- come compressed, making it impossible to loosen them.
Page 37: Fig. 16: Turbocharger Centre Of Gravity
Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.2 Removing the turbocharger 3.2.3 Positioning the turbocharger for storage WARNING Risk of tipping If the turbocharger is not positioned stably, it may tip over. This can result in serious personal injury.
Page 38: Installing The Turbocharger
Always use new gaskets and insert them carefully into the slot. The oil is supplied (02) and drained (03) through the bracket (01). The necessary sealing is provided by O-rings. The O-rings are not included in the ABB scope of delivery. Fig. 17: Inserting gaskets into the bracket...
Page 39: Fig. 18: Inserting The Threaded Rods
The threaded rods and nuts for fastening the turbocharger on the bracket are not included in the ABB scope of delivery. The clamping nuts are included in the ABB scope of delivery. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N...
Page 40: Fig. 20: Placing The Turbocharger On The Bracket
Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.3 Installing the turbocharger 3.3.3 Placing the turbocharger on the bracket Fig. 20: Placing the turbocharger on the bracket Oil-cooled bearing casing C Fixing with clamping nut Water-cooled bearing casing D Fixing with standard nut Make sure that covers of the oil and water connections are removed.
Page 41: Table 6: Tightening Torque For Standard Nuts
Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.3 Installing the turbocharger Observe the instructions for the fastening variant at hand. ¡ Fastening the turbocharger with a standard nut →39 (A130 - A140) ¡ Fastening the turbocharger with a clamping nut →40 (A140 and A145) 3.3.4...
Page 42: Fig. 21: Preparing The Clamping Nut For The Tightening Procedure
Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.3 Installing the turbocharger 3.3.5 Fastening the turbocharger with a clamping nut Preparations for tightening the clamping nut CAUTION Do not clean pressure screws (04) The pressure screws are equipped with a permanent sliding layer that must not be removed.
Page 43: Fig. 22: Tightening Pressure Screws
Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.3 Installing the turbocharger Tightening pressure screws Fig. 22: Tightening pressure screws Product Fixing screw [mm] Tightening torques [Nm] A140 A145 Table 7: Torque-controlled tightening of the pressure screws 1. Screw in pressure screws crosswise by hand until reaching the stop.
Page 44: Fig. 23: Connecting The Speed Sensor
Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.3 Installing the turbocharger 3.3.6 Connecting the turbocharger Fig. 23: Connecting the speed sensor Connect cable to speed sensor (86515). Connect all gas, water and air lines according to the instructions of the enginebuilder.
Page 45: Fig. 25: Attaching The Support
Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.3 Installing the turbocharger 3.3.7 Attaching the support Fig. 25: Attaching the support If present: Attach support (61301) to engine support or to a connecting piece. © Copyright 2021 ABB. All rights reserved.
Page 46: Commissioning
Operation Manual / A130-M.. - A145-M.. 4 Commissioning / 4.1 Oil supply Commissioning Oil supply 4.1.1 Introduction In all operating states, a functioning and carefully executed oil supply is an important pre- requisite for trouble-free operation of the turbocharger. The lubrication of the turbocharger is usually carried out with oil from the engine oil circula- tion.
Page 47: Fig. 26: Oil Orifice
Operation Manual / A130-M.. - A145-M.. 4 Commissioning / 4.1 Oil supply 4.1.5 Oil orifice in the bearing casing Fig. 26: Oil orifice Bearing casing Oil orifice Circlip With an oil inlet pressure of more than 3 bar of overpressure (with engine under load) up- stream of the turbocharger, the bearing casings are equipped with an orifice at the oil inlet as standard.
Page 48: Inspection Procedures
Operation Manual / A130-M.. - A145-M.. 4 Commissioning / 4.2 Inspection procedures Inspection procedures 4.2.1 Introduction Inspection procedures include preventative visual controls, monitoring and measuring work before and during commissioning. Inspection procedures enable changes to the turbochar- ger to be detected. Machine damage can be prevented.
Page 49 Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids during the initial hours of operation. Continual escape of an oily fluid indicates an oil leak. If there is a leak, contact an ABB Turbocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 50: Commissioning After Taking Out Of Operation
Operation Manual / A130-M.. - A145-M.. 4 Commissioning / 4.3 Commissioning after taking out of operation Commissioning after taking out of operation If present Remove cover plates (blind flanges) from the compressor casing, the gas inlet and the gas outlet.
Page 51: Monitoring Operation
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbocharging recommends installing a "P" manometer immediately upstream of the turbocharger oil inlet before the orifice. If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values.
Page 52: Table 9: Lubricating Oil Temperature At The Inlet
Table 10: Lubricating oil temperature at the outlet If the turbocharger has been operated for a longer period of time outside the admissible range, ABB Turbocharging recommends having the turbocharger inspected by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 53: Exhaust Gas Temperature Before Turbine
Operation Manual / A130-M.. - A145-M.. 5 Monitoring operation / 5.2 Exhaust gas temperature before turbine Exhaust gas temperature before turbine CAUTION Factors influencing replacement intervals Operation above the operating limits defined on the rating plate can shorten the recommended replacement intervals considerably.
Page 54: Turbocharger Speed
Operation Manual / A130-M.. - A145-M.. 5 Monitoring operation / 5.3 Turbocharger speed Turbocharger speed 5.3.1 Introduction A speed measuring system enables the constant monitoring of the turbocharger speed. CAUTION Do not strain cables If you pull the speed measurement cables too hard, contacts can be pulled out.
Page 55 Check the pressure loss of the alternative air inlet and compare it with normal values. If the engine can be stopped temporarily: Inspect air lines, gas piping and the turbochargers and remedy any malfunctions. In any case, contacting the nearest ABB Turbocharging Service Station is recommended. 5.3.4 Malfunctions on the speed measurement system...
Page 56: Fig. 28: Replacing The Speed Sensor
Wear safety gloves when disassembling the speed sensor. Wear safety gloves to protect against thermal hazards. The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional gasket is required during assembly. Fig. 28: Replacing the speed sensor...
Page 57: Operation And Service
Operation Manual / A130-M.. - A145-M.. 6 Operation and service / 6.1 Noise emission Operation and service Noise emission WARNING Danger due to noise Exposure to noise can harm the hearing system, impair health and the psy- chological state and may lead to lack of attention and irritation.
Page 58: Fig. 29: Noise Insulation, Bellows
Operation Manual / A130-M.. - A145-M.. 6 Operation and service / 6.1 Noise emission Suggestion for noise insulation, bellows Fig. 29: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover ©...
Page 59: Service Work
Agree on a specific service interval with ABB Turbocharging. To prevent machine damage caused by ageing and downtime, we recommend having an in- spection carried out by an ABB Turbocharging Service Station no later than 5 years after the last service.
Page 60 Service work according to data on the rating plate (Usually after 8000 … 16000 operating hours) The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station. The following work can be carried out as preparation.
Page 61: Fig. 30: Replacing The Protective Grid
6 Operation and service / 6.2 Service work 6.2.5 Other service work If a protective grid is installed in the gas outlet casing (61001) by ABB: Fig. 30: Replacing the protective grid Remove the protective grid (61205) after 50000 hours and replace it with a new protect- ive grid.
Page 62 Operation Manual / A130-M.. - A145-M.. 6 Operation and service / 6.2 Service work 6.2.6 Entries in the engine logbook The monitoring of the engine system enables conclusions to be drawn on the behaviour of the turbocharger. The following operating data and measured values must be entered regularly in the engine logbook of the enginebuilder: ¡...
Page 63: Expected Replacement Intervals
Operation Manual / A130-M.. - A145-M.. 6 Operation and service / 6.3 Expected replacement intervals Expected replacement intervals Rotating components The recommended replacement intervals of the compressor and turbine wheels are spe- cified with the aid of the safety concept for rotating parts (SIKO) and dependent on the op- erating conditions.
Page 64 Operation Manual / A130-M.. - A145-M.. 6 Operation and service / 6.3 Expected replacement intervals Influencing parameters The specified values are guideline values and are not guaranteed. The actual values can devi- ate considerably from the guideline values, for example, due to the following influences: ¡...
Page 65: Stopping The Engine
– 550 °C with insulated casing – 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication must be ensured until the rotors come to a standstill. ABB Turbocharging recommends post-lubrication for 10 minutes. Observe the oil pressure specified for post-lubrication (see Table 8: Lubricating oil pres-...
Page 66: Periodic Maintenance Work
Table 13: Maintenance table [h] = Hours of operation If the maintenance intervals are incompatible with operation of the engine, contact ABB Turbocharging. ABB Turbocharging recommends having mechanical cleaning carried out by an ABB Tur- bocharging Service Station during the service work (see also chapter...
Page 67: Cleaning The Compressor During Operation
Periodic cleaning during operation delays any major increase in contamination. The cleaning method is suitable as long as the contamination has not progressed far. Very heavily con- taminated components can no longer be cleaned using this method. In this case, ABB Tur- bocharging recommends mechanical cleaning of the contaminated components.
Page 68 The compressor is cleaned during operation using the wet cleaning method. This is carried out at an engine load of 50 … 85%. This cleaning method is tested and approved by ABB Turbocharging. V-engines On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended.
Page 69: Fig. 31: Carrying Out Wet Cleaning Of Compressor
Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.2 Cleaning the compressor during op- eration 72000 Compressor casing 27000 External water pressure vessel 27005 Sealing plug Water pipe to filter silencer or air suction branch Pressurized air inlet pipe Valve activator Pressurized air from the compressor casing (72000) of the turbocharger passes through the...
Page 70: Cleaning The Turbine During Operation
Periodic cleaning during operation delays any major increase in contamination. The cleaning method is suitable as long as the contamination has not progressed far. Very heavily con- taminated components can no longer be cleaned using this method. In this case, ABB Tur- bocharging recommends mechanical cleaning of the contaminated components.
Page 71 Cleaning method The turbine components are cleaned during operation using the wet cleaning method. This cleaning method is tested and approved by ABB Turbocharging. The precondition for wet cleaning is that the enginebuilder approves the process and these regulations are observed.
Page 72: Table 15: Turbine Wet Cleaning, Recommended Operating State
Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.3 Cleaning the turbine during opera- tion 7.3.5 Prerequisites Characteristic/component Conditions Engine load (guideline value) 20 … 40 % *) Turbine inlet temperature T before water injection 350 … 430 °C Stabilisation phase after T has been reached 10 minutes...
Page 73: Fig. 32: Carrying Out Wet Cleaning Of Turbine
→71). Close the stop valve (02) after 10 minutes. Wait for 10 minutes; do not change the load during this stabilisation phase. If the cleaning result is unsatisfactory or there is water leakage, contact an ABB Turbochar- ging Service Station. Product Temperature be-...
Page 74: Cleaning Components Mechanically
Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically Cleaning components mechanically 7.4.1 Preparation CAUTION Component damage and corrosion If mechanical cleaning is carried out incorrectly, this can lead to damage and corrosion on the components.
Page 75: Fig. 33: Cleaning The Filter Silencer
Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically 7.4.2 Cleaning the filter silencer Fig. 33: Cleaning the filter silencer 81135 Filter silencer body 81266 Cover grid 81136 Absorption segment 81270 Tension band 81137 Sheet-metal covering...
Page 76 When cleaning, note that the absorption segments (81136) must only be cleaned lightly with compressed air, a soft brush or a moist cleaning cloth. Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station. Fitting the filter silencer (see Fig. 33: Cleaning the filter silencer →73)
Page 77: Fig. 34: Compressor-End, Non-Rotating Parts
Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically 7.4.3 Compressor-end, non-rotating parts WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con- tact with them may be harmful to health.
Page 78: Fig. 35: Turbine End, Non-Rotating Parts
Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically 7.4.4 Turbine-end, non-rotating parts WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con- tact with them may be harmful to health.
Page 79 Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically Repeat the soaking and brushing process if necessary. Use clean water to remove all traces of solvent from parts. Dry components completely. Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur- bocharger.
Page 80 Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically 7.4.6 Cleaning the cartridge group on compressor end CAUTION Selection of the cleaning agent Cleaning agents which contain chlorine attack metals. Use only pH-neutral cleaning agents which do not attack metals.
Page 81: Fig. 36: Soaking The Turbine End
Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically 7.4.7 Cleaning the cartridge group on turbine end Soaking the contamination Baked layers of contamination from heavy fuel oil or coked oil occur at the turbine end. The contamination can be removed by soaking and brushing.
Page 82 Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically WARNING Heating up of cleaning agents and operating fluids When cleaning agents or operating fluids are heated up, explosive vapours can be produced which are hazardous to health.
Page 83 Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically CAUTION Water and dirt in the cartridge group If water or dirt enters the cartridge group, this can impair the function of the turbocharger and damage parts inside the cartridge group.
Page 84: Eliminating Malfunctions
To prevent significant loss of efficiency, specific tolerances must be fulfilled. ¡ If there is any doubt about the extent of the rubbing, contact an ABB Tur- bocharging Service Station. ¡...
Page 85: Malfunctions During Operation
Turbochar- Turbine and/or nozzle ring severely con- Clean (see chapter Periodic mainten- taminated ance work →64) Rotor components or bearing damaged Contact ABB Turbocharging Service Station Engine Defects on the connected cylinders in Contact enginebuilder pulse charging Pipes Defects, such as leaks, in the exhaust...
Page 86: Table 24: Malfunctions During Operation - Exhaust Gas Temperature Too High
Operation Manual / A130-M.. - A145-M.. 8 Eliminating malfunctions / 8.2 Malfunctions during operation Exhaust gas temperature too high Engine performance and engine speed unchanged Possible causes Remedy Turbocharger Insufficient air, for example, when fil- Clean (see chapter Periodic mainten-...
Page 87: Table 26: Malfunctions During Operation - Charge Air Pressure Too High
Operation Manual / A130-M.. - A145-M.. 8 Eliminating malfunctions / 8.2 Malfunctions during operation Charge air pressure too high Engine performance and engine speed unchanged, suction condition normal Possible causes Remedy Turbochar- Manometer display not correct Replace manometer Increased speed due to contamination...
Page 88: Turbocharger Is Surging
Gradually reduce the engine load. Have the cause clarified and remedied immediately by an ABB Turbochar- ging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharging Service Station. Possible causes Remedy...
Page 89: Malfunctions When Stopping
Check clearances (see chapter Measuring clear- ance A and B →105). If clearances are outside the tolerance or if in doubt, contact an ABB Turbochar- ging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station.
Page 90: Speed Measurement System
Table 34: Malfunction of the speed measurement system – Measured speed too low If none of the measures described above remedy the malfunction, have the speed measure- ment system checked by an ABB Turbocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 91: Dismantling And Fitting
ABB Turbocharging Service Station. Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB must be tightened so they are tight-fitting. © Copyright 2021 ABB. All rights reserved.
Page 92: Material Required
Visually inspect for corrosion, cracks, deformation and wear. Damaged tools must no longer be used and must be replaced. Swivel lifting eyes Swivel lifting eyes are required for the safe lifting of loads, which are not supplied by ABB. Fig. 37: Swivel lifting eyes Product...
Page 93: Fig. 38: Starpoint Ring Nut Vrm
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.2 Material required Starpoint ring nuts Two ring nuts (M16) are required for safer lifting of the cartridge group, which are not in- cluded in the ABB scope of delivery.
Page 94: Weights Of Individual Parts
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.3 Weights of individual parts Weights of individual parts The specified weights of the individual parts or assemblies are rounded-up standard values. Fig. 39: Weights of assemblies Designation A130 A135...
Page 95: Removing The Air Inlets
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.4 Removing the air inlets Removing the air inlets Mark the casing position for assembly. Fig. 40: Removing the air inlets 1. Attach lifting gear to the filter silencer (81000) or air suction branch (82000).
Page 96: Removing The Gas Outlet Casing
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.5 Removing the gas outlet casing Removing the gas outlet casing Removing the insulation Fig. 41: Removing the insulation Remove gas outlet casing insulation. © Copyright 2021 ABB. All rights reserved.
Page 97: Removing The Gas Outlet Flange
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.6 Removing the gas outlet flange Mark the casing position for assembly. Fig. 42: Removing the gas outlet casing 1. Attach lifting gear to the gas outlet casing (61001). 2. Loosen and remove nuts (51009).
Page 98: A130 A135 A140 A145
≤ 65 Nm Table 37: 3 press-off screws * not included in the ABB scope of delivery 1. Press off and remove the gas outlet flange (57002) with screws (01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tightening torque, contact an ABB Turbocharging Service Station.
Page 99: Fig. 44: Removing The Gas Outlet Flange
6x M12 x 30 Table 38: 6 press-off screws * not included in the ABB scope of delivery. 1. Evenly press off and remove the gas outlet flange (57002) with screws (01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tight- ening torque, contact an ABB Turbocharging Service Station.
Page 100: Removing The Compressor Casing
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.7 Removing the compressor casing Removing the compressor casing Removing the compressor casing Mark the casing position for assembly. Fig. 45: Removing the compressor casing 1. Loosen screws (72011) and remove together with fastening strips (72012).
Page 101: Wall Insert
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.7 Removing the compressor casing Dismantling the wall insert Fig. 46: Dismantling the wall insert 1. Knock the wall insert (77000) out of the compressor casing (72000) with a plastic tip hammer.
Page 102: Pressing Off The Casing
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.8 Pressing off the casing Pressing off the casing CAUTION Axial force of the press-off tool Using the press-off tool (90042), a high level of axial force can be generated.
Page 103: Removing The Cartridge Group
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.9 Removing the cartridge group Removing the cartridge group Fig. 48: Removing insulation sheets If present: Remove the insulation sheets (01, 02, 03). Mark the casing position for assembly. Do not remove oil orifice (if present)
Page 104: Fig. 50: Removing Cartridge Group 1
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.9 Removing the cartridge group Fig. 50: Removing cartridge group 1 1. Treat threads of studs (51006) with penetrating oil and leave to take effect. 2. Undo nuts (51007) and remove Verbus Ripp® washers (51003) together with fastening strips (51002).
Page 105: Removing The Nozzle Ring
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.10 Removing the nozzle ring 9.10 Removing the nozzle ring Fig. 52: Removing the nozzle ring 1. If present: Remove the metal C-ring (51105). 2. Position the fastening strips (51002) in place.
Page 106: Installing The Cartridge Group On The Service Support
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.11 Installing the cartridge group on the service support 9.11 Installing the cartridge group on the service support Fig. 53: Installing the cartridge group on the service support 1. Remove ring nuts (VRM).
Page 107: Measuring Clearance A And B
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 108: Nozzle Ring Compression Pd
Table 40: Nozzle ring compression PD 1. Measure dimensions A, B and S on cleaned surfaces. 2. Calculate compression (PD). If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar- ging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 109: Installing The Nozzle Ring
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.14 Installing the nozzle ring 9.14 Installing the nozzle ring Fig. 56: Installing the nozzle ring *) Variant A1 or A2, depending on the nozzle ring version. 1. Fit the lamellar sealing ring (56005) in the correct slot (see detail A1/A2). When doing this, pay attention to correct winding of the lamellar sealing ring (see detail B).
Page 110: Installing The Cartridge Group
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.15 Installing the cartridge group 9.15 Installing the cartridge group Lifting the cartridge group and rotating it by 90° Fig. 57: Lifting the cartridge group and rotating it by 90°...
Page 111: Fig. 58: Installing The Cartridge Group
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.15 Installing the cartridge group Installing the cartridge group Fig. 58: Installing the cartridge group Product Size Tightening torque [Nm] A130 A135 A140 A145 Table 41: Tightening torque (51007) 1. Coat thread of studs (51006) with high-temperature grease.
Page 112: Fig. 59: Turbine Casing Insulation / Burst Protection
9 Dismantling and fitting / 9.15 Installing the cartridge group WARNING The turbine casing insulation supplied by ABB also acts as burst protection Serious injuries or accidents resulting in fatalities can occur if the turbine casing insulation (01) supplied by ABB is removed. A burst protection is in- tegrated into this turbine casing insulation supplied by ABB.
Page 113: Installing The Compressor Casing
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.16 Installing the compressor casing 9.16 Installing the compressor casing Fitting the wall insert and the diffuser A130 - A140 A145 Product Size Tightening torque [Nm] A130 A135 A140 A145 Table 42: Tightening torque (79041)
Page 114: Fig. 60: Installing The Compressor Casing
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.16 Installing the compressor casing Installing the compressor casing Fig. 60: Installing the compressor casing Product Size Tightening torque [Nm] A130 A135 A140 A145 Table 43: Tightening torque (72011) 1. Fit new O-ring (42012).
Page 115: Measuring Radial Clearances N And R
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 116: Installing The Air Inlets
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.18 Installing the air inlets 9.18 Installing the air inlets Fig. 62: Installing the air inlets Product Size Tightening torque [Nm] A130 A135 A140 A145 Table 45: Tightening torque (72020) 1. Secure lifting gear to filter silencer (81000).
Page 117: Installing The Gas Outlet Flange
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.19 Installing the gas outlet flange 9.19 Installing the gas outlet flange Fig. 63: Installing the gas outlet flange 1. If present: Insert the metal C-ring (57003) into the turbine casing (51000) and secure with high-vacuum grease.
Page 118: Fitting The Insulation Of The Turbine Casing
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.20 Fitting the insulation of the turbine casing 9.20 Fitting the insulation of the turbine casing Fig. 64: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see...
Page 119: Installing The Gas Outlet Casing
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.21 Installing the gas outlet casing 9.21 Installing the gas outlet casing Fig. 65: Installing the gas outlet casing Product Size Tightening torque [Nm] A130 A135 A140 A145 Table 46: Tightening torque (51009) 1.
Page 120: Fig. 66: Fitting The Insulation
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.21 Installing the gas outlet casing Fitting the insulation Fig. 66: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →119).
Page 121: Table Of Tightening Torques
Table 47: Tightening torques *) With the variant "insulation with integrated burst protection", this position can be ig- nored. 16d **) applies to the burst protection mounting of A130-M and A135-M turbochargers on railway applications © Copyright 2021 ABB. All rights reserved.
Page 122: Fig. 68: Tightening Torques For Insulation
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.22 Table of tightening torques Fig. 68: Tightening torques for insulation The following tightening torques must be observed for the specified screw connections: Position Part number A130 A135 A140 A145 16a / - -...
Page 123: Taking Out Of Operation At Short Notice
Operation Manual / A130-M.. - A145-M.. 10 Taking out of operation at short notice / 10.1 Possible emergency repairs Taking out of operation at short notice 10.1 Possible emergency repairs WARNING Danger of fire and explosion due to lubricating oil leaks Leaking oil may ignite on hot surfaces.
Page 124: Installing The Replacement Turbocharger
The repair of a cartridge group requires special tools and the expertise of an ABB Turbochar- ging Service Station. The rotating parts rotate extremely quickly, and are sensitive to unbal- ance.
Page 125: Fitting The Cover Plate
Operation Manual / A130-M.. - A145-M.. 10 Taking out of operation at short notice / 10.4 Fitting the cover plate 10.4 Fitting the cover plate Remove turbocharger (see chapter Removing and Installing →30). ¡ Gas outlet casing removed Fit the turbine casing with the gas outlet casing into the gas pipe again.
Page 126: Cover Plate Drawing
10 Taking out of operation at short notice / 10.5 Cover plate drawing 10.5 Cover plate drawing The cover plate is not included in the ABB scope of delivery and must be manufactured by the operating company according to the following drawing. Material: General structural steel, in accordance with DIN EN 10025-2.
Page 127: Mothballing The Turbocharger
If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking the engine out of operation: Dismantle the turbocharger. The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur- bocharging Service Station. Clean all parts.
Page 128: Taking The Engine Out Of Operation For More Than 12 Months
¡ The casings of the turbocharger remain attached to the engine, the rotor and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately ¡ The turbocharger is completely removed, either as a whole unit or in individual parts For the measures always necessary for preparing the turbocharger parts for mothballing, see section Taking the engine out of operation for up to 12 months, subsection Preparations...
Page 129: Disposing Of Turbocharger Components
Operation Manual / A130-M.. - A145-M.. 12 Disposing of turbocharger components / Disposing of turbocharger components WARNING Handling damaged thermal insulation Damaged thermal insulation can lead to dust exposure. The glass fibres can cause mechanical irritation of the eyes, skin, and respiratory tracts.
Page 131: Spare Parts
O-ring 79041 Counter-sunk screw 81010/ 82010 O-ring Table 50: Customer spare part set 97070 * This gasket can only be installed when a gas outlet casing from ABB is used. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 132: Spare Part - Illustrations
Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations 13.3 Spare part – Illustrations The spare parts lists shown below are only available in English. Cartridge, oil cooled 42167** 42169** 42170** 42171** 42201** 42168**...
Page 133: Table 51: Spare Parts - Cartridge, Oil Cooled
Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Part no. Designation 42197 Safety ring 42201** Clamping nut Table 51: Spare parts - Cartridge, oil cooled Cartridge, water cooled 42167** 42201** 42190 42166** 42194(p) 42047(p)
Page 134 Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Turbine casing, 1 inlet 51302** 51303** 51301** 51027(p) 57003** 51009 51008 51006 57002 51002 51003 51007 51102** TW03 51107** TW04 51000 57210 56005 51101 56001...
Page 135: Table 53: Spare Parts - Turbine Casing, 1 Inlet
Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Part no. Designation 51303** Screw plug 51500 Burst protection TW02, TW04 56001 Nozzle ring 56005 Lamellar sealing ring 57002 Gas-outlet flange 57003** Metal C-ring 57210 Burst ring Table 53: Spare parts - Turbine casing, 1 inlet...
Page 136 Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Turbine casing, 2 inlets 51027(p) 51301** 51302** 51303** 51009 51008 51006 51002 57002 51003 51007 57003** 51010** TW03 51000 57210 51101 56005 51102 56001 51105* **...
Page 137: Table 54: Spare Parts - Turbine Casing, 2 Inlets
Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Part no. Designation 56005 Lamellar sealing ring 57002 Gas-outlet flange 57003** Metal C-ring 57210 Burst ring Table 54: Spare parts - Turbine casing, 2 inlets © Copyright 2021 ABB. All rights reserved.
Page 138: Table 55: Spare Parts - Gas Outlet Casing, Axial
Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Gas outlet casing, axial 61001 61002* GH02 61001** GH02 GHV03 61001** GH02 GHV08 ** = if provided * = Available within the spare part set only HZTL443467 Mod.A...
Page 139: Table 56: Spare Parts - Gas Outlet Casing, Radial
Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Gas outlet casing, radial 61100 GW03 61205** 61202 61008* ** 61201 61005(p) 61200 61202 61201 (p) = pre-assembled 61002* 61301** 61001 61100 ** = if provided * = Available within the spare part set HZTL443466 Mod.
Page 140: Table 57: Spare Parts - Compressor Casing
Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Compressor casing 72060 72062 72061 72010** 72012 (A145 only) 79041* 79040 79000 77000 77005* 72011 72080 72000 72020 72006(p) (p) = pre-assembled ** = if provided...
Page 141: Table 58: Spare Parts - Filter Silencer
Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Filter silencer 81000 81137 81136 81005 81006 81135 81171 81170 81266 81270 81265** 81010* 81271 (p) = pre-assembled * = Available within the spare part set HZTL443469 Mod.
Page 142: Table 59: Spare Parts - Air Suction Branch Axial
Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Air suction branch axial 82005 82010* 82007 82008 82006 82000 * = Available within the spare part set HZTL443013 Mod. D Part no. Designation 82000...
Page 143: Table 60: Spare Parts - Air Suction Branch Radial
Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Air suction branch radial 82007 82008 82000 82010* 82006 82005 * = Available within the spare part set HZTL443012 Mod. D Part no. Designation 82000...
Page 144: Table 61: Spare Parts - Bearing Casing, Oil Cooled
Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Bearing casing, oil cooled 42006** 42005** 42401** 42001 42400 42008* 42047(p) 42194(p) 42302* ** 42189(p) 42188(p) 42305* 42306* 42301 42197 42196 (p) = pre-assembled ** = if provided * = Available within the spare part set HZTL443373 Mod.
Page 145: Table 62: Spare Parts - Bearing Casing, Water Cooled
Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Bearing casing, water cooled Railway and Traction 42142*(p) Application 42141*(p) 42140*(p) 42403* ** 42001 42056** 42006** 42005** 42006** 42008* 42401** 42400 42047(p) 42194(p) 42302* **...
Page 146: Table 63: Spare Parts - Rotor And Bearing Parts
Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Rotor and bearing parts 32109** 42302* ** 21000 21000 21011** 21006* ** 21002* 32103* 32104* 32111* 42002 32167* 32109 32102* 32114* 32112 32113* 32110 32101*...
Page 147: Tools
90042 Press-off tool 90070 Extraction device Table 64: Customer tool set 90000 Tool sets can be ordered from any ABB Turbocharging Service Station. The following spe- cifications must be included in the order: ¡ Turbocharger type ¡ Designation and part number of the tool set.
Page 148: Figures
Operation Manual / A130-M.. - A145-M.. Figures Figures Fig. 1: Serial number (01) on the rating plate ... 4 Fig. 32: Carrying out wet cleaning of turbine.... 71 Fig. 2: Layout and function of the turbocharger..6 Fig. 33: Cleaning the filter silencer ......73 Fig. 3: Compressor wheel cooling ........
Page 149 Operation Manual / A130-M.. - A145-M.. Figures Fig. 63: Installing the gas outlet flange ....115 Fig. 64: Fitting the insulation........116 Fig. 65: Installing the gas outlet casing ....117 Fig. 66: Fitting the insulation........118 Fig. 67: Tightening torques ........119 Fig. 68: Tightening torques for insulation .... 120 Fig. 69: Fitting the cover plate........
Page 150: Tables
Operation Manual / A130-M.. - A145-M.. Tables Tables Table 1: Definition of pictograms ....... 9 Table 26: Malfunctions during operation – Charge air pressure too high ............85 Table 2: Personal protective equipment to be worn at all times ..............14 Table 27: Malfunctions during operation – Engine performance losses............
Page 151 Operation Manual / A130-M.. - A145-M.. Tables Table 55: Spare parts - Gas outlet casing, axial ..136 Table 56: Spare parts - Gas outlet casing, radial .. 137 Table 57: Spare parts - Compressor casing ... 138 Table 58: Spare parts - Filter silencer...... 139 Table 59: Spare parts - Air suction branch axial...

This manual is also suitable for:

A135 A140 A135-m66 A 145

ABB A130 Operation Manual

Table of Contents

1 Introduction

2 Safety

3 Removing and Installing

4 Commissioning

5 Monitoring Operation

6 Operation and Service

7 Periodic Maintenance Work

8 Eliminating Malfunctions

9 Dismantling and Fitting

Weights of Individual Parts

10 Taking out of Operation at Short Notice

11 Mothballing the Turbocharger

12 Disposing of Turbocharger Components

13 Spare Parts

14 Tools

Figures

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Summary of Contents for ABB A130

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Table of Contents